Detection Pins to Determine Presence of Surgical Instrument and Adapter on Manipulator

ABSTRACT

An instrument carriage provides control of a surgical instrument coupled to the instrument carriage. The instrument carriage includes a control surface that is coupled to the surgical instrument to provide the control. A detection pin having a first proximal end that extends from the control surface is coupled to the instrument carriage. A magnet is fixed to a distal end of the detection pin. A carriage controller provides an indication that the surgical instrument is coupled to the instrument carriage when movement of the detection pin causes an output signal from a Hall effect sensor to exceed a threshold value that is stored in the carriage controller as part of a calibration procedure during the assembly of the instrument carriage. Surgical instrument removal may be indicated when detection pin movement causes the output signal to be less than an instrument removal threshold value of less than the instrument threshold value.

This application claims a right of priority to the following earlierfiled applications:

U.S. 61/954,497 17 Mar. 2014 (17-03-2014) U.S. 61/954,502 17 Mar. 2014(17-03-2014) U.S. 61/954,557 17 Mar. 2014 (17-03-2014) U.S. 61/954,57117 Mar. 2014 (17-03-2014) U.S. 61/954,595 17 Mar. 2014 (17-03-2014) U.S.62/019,318 30 Jun. 2014 (30-06-2014) U.S. 62/103,991 15 Jan. 2015(15-01-2015) U.S. 62/104,306 16 Jan. 2015 (16-01-2015)

Each of these applications is specifically incorporated herein byreference to the greatest extent permitted.

FIELD

Embodiments of the invention relate to the field of surgical instrumentadapters; and more specifically, to detection pins for determiningpresence of surgical instruments and instrument adapters on teleoperatedmanipulators.

BACKGROUND

Minimally invasive medical techniques have been used to reduce theamount of extraneous tissue which may be damaged during diagnostic orsurgical procedures, thereby reducing patient recovery time, discomfort,and deleterious side effects. Traditional forms of minimally invasivesurgery include endoscopy. One of the more common forms of endoscopy islaparoscopy, which is minimally invasive inspection or surgery withinthe abdominal cavity. In traditional laparoscopic surgery, a patient'sabdominal cavity is insufflated with gas, and cannula sleeves are passedthrough small (approximately 12 mm) incisions in the musculature of thepatient's abdomen to provide entry ports through which laparoscopicsurgical instruments can be passed in a sealed fashion.

The laparoscopic surgical instruments generally include a laparoscopefor viewing the surgical field and surgical instruments having endeffectors. Typical surgical end effectors include clamps, graspers,scissors, staplers, and needle holders, for example. The surgicalinstruments are similar to those used in conventional (open) surgery,except that the working end or end effector of each surgical instrumentis separated from its handle by an approximately 30 cm. long extensiontube, for example, so as to permit the operator to introduce the endeffector to the surgical site and to control movement of the endeffector relative to the surgical site from outside a patient's body.

In order to provide improved control of the end effector, it may bedesirable to control the surgical instrument with teleoperatedactuators. The surgeon may operate controls on a console to indirectlymanipulate the instrument that is connected to the teleoperatedactuators. The surgical instrument is detachably coupled to theteleoperated actuators so that the surgical instrument can be separatelysterilized and selected for use as needed instrument for the surgicalprocedure to be performed. The surgical instrument may be changed duringthe course of a surgery.

Performing surgery with teleoperated surgical instruments creates newchallenges. One challenge is the need to maintain the region adjacentthe patient in a sterile condition. However, the motors, sensors,encoders and electrical connections that are necessary to control thesurgical instruments typically cannot be sterilized using conventionalmethods, e.g., steam, heat and pressure or chemicals, because they wouldbe damaged or destroyed in the sterilization process.

Another challenge with teleoperated surgery systems is that a number ofconnections are required between the surgical instrument and theteleoperated actuator and its controller. Connections are required totransmit the actuator forces, electrical signals, and data. This makesthe attachment of the surgical instrument to the teleoperated actuatorand its controller complex.

Still another challenge with teleoperated actuated teleoperated surgerysystems is that an operating room is not an ideal environment forpreparing precision mechanical assemblies.

It would be desirable to provide a way of determining if a sterileadapter and/or a surgical instrument is present on a teleoperatedmanipulator.

SUMMARY

A teleoperated actuated surgical system includes a surgical instrument,a teleoperated actuated surgical instrument manipulator, and aninstrument sterile adapter (ISA). The ISA is placed between the couplingof the surgical instrument and the teleoperated actuated surgicalinstrument manipulator in order to provide a sterile coupling point whenthere is a need to exchange one surgical instrument for another. Acarriage portion of the teleoperated actuated surgical instrumentmanipulator includes a plurality of detection pins used to detection thepresence of the ISA and a surgical instrument.

Herein, the disclosure provides embodiments pertaining to reliablydetecting the engagement of the ISA with the teleoperated actuatedsurgical instrument manipulator and the engagement of the surgicalinstrument with the ISA. Additionally, one or more of the embodimentsaccomplishes the reliable detection of both engagements using onemechanism (e.g., a plurality of detection pins and correspondingsensors). In one embodiment, a first set of one or more detection pinsmay be used to detect the presence of the ISA while a second set of oneor more detection pins may be used to detect the presence of thesurgical instrument. Alternatively, the first set of one or moredetection pins may be used to detect the presence of both the ISA andthe surgical instrument.

In one embodiment, the detection of the presence of the ISA may beaccomplished by determining the distance between an analog Hall effectsensor and a magnet attached to a proximal end of a detection pin. Whenthe distance between the analog Hall effect sensor and a face of themagnet is within a first range, the analog Hall effect sensor may outputa first predetermined voltage identifying the presence of the ISA. Inaddition, the output of the first predetermined voltage may signify theengagement of the ISA with the carriage of the teleoperated actuatedsurgical instrument manipulator. When the distance between the analogHall effect sensor and the face of the magnet is within a second rangebeing smaller than the first range, the analog Hall effect sensor mayoutput a second predetermined voltage identifying the presence of thesurgical instrument. Additionally, the output of the secondpredetermined voltage may signify the engagement of the surgicalinstrument with the ISA. Other features and advantages of the presentinvention will be apparent from the accompanying drawings and from thedetailed description that follows below.

Other features and advantages of the present invention will be apparentfrom the accompanying drawings and from the detailed description thatfollows below.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may best be understood by referring to the followingdescription and accompanying drawings that are used to illustrateembodiments of the invention by way of example and not limitation. Inthe drawings, in which like reference numerals indicate similarelements:

FIG. 1 is a simplified perspective view of a teleoperated actuatedsurgical system with a teleoperated controlled surgical instrumentinserted through a port in a patient's abdomen.

FIG. 2 is a plan view of a surgical instrument for use with ateleoperated actuator.

FIG. 3A is an illustration of an exemplary embodiment of a coupling of asurgical instrument, a carriage of a teleoperated actuated surgicalinstrument manipulator and an instrument sterile adapter (ISA).

FIG. 3B is an illustration of the coupler system of FIG. 3A with theparts separated.

FIG. 4 is an illustration of an exemplary embodiment of a controlsurface of the carriage of FIG. 1 from a top-down perspective includinga plurality of the detection pins.

FIG. 5 is an illustration of an exemplary embodiment of the detectionpins relative to the circuit board 561 and the sensors.

FIG. 6A is a sectional illustration of the plurality of detection pinsof the carriage of FIG. 4 relative to the surgical instrument, the ISAand the circuit board prior the engagement of the ISA with the carriagetaken along section line 6A-6A in FIG. 4. FIG. 6B is a sectional of theplurality of detection pins of the carriage of

FIG. 4 relative to the ISA and the circuit board upon the engagement ofthe ISA with the carriage taken along section line 6A-6A in FIG. 4.

FIG. 6C is a sectional illustration of the plurality of detection pinsof the carriage of FIG. 4 relative to the surgical instrument, the ISAand the circuit board upon the engagement of the surgical instrumentwith the ISA taken along section line 6A-6A in FIG. 4.

FIG. 7 is a graph showing the digital output of an exemplary analog Halleffect sensor as a function of the distance between a magnet and theanalog Hall effect sensor.

FIGS. 8A-8D illustrate a plurality of depression states for an exemplaryembodiment of a detection pin.

DESCRIPTION OF EMBODIMENTS

In the following description, numerous specific details are set forth.However, it is understood that embodiments of the invention may bepracticed without these specific details. In other instances, well-knowncircuits, structures, and techniques have not been shown in detail inorder not to obscure the understanding of this description.

In the following description, reference is made to the accompanyingdrawings, which illustrate several embodiments of the present invention.It is understood that other embodiments may be utilized, and mechanicalcompositional, structural, electrical, and operational changes may bemade without departing from the spirit and scope of the presentdisclosure. The following detailed description is not to be taken in alimiting sense, and the scope of the embodiments of the presentinvention is defined only by the claims of the issued patent.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.Spatially relative terms, such as “beneath”, “below”, “lower”, “above”,“upper”, and the like may be used herein for ease of description todescribe one element's or feature's relationship to another element(s)or feature(s) as illustrated in the figures. It will be understood thatthe spatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the exemplary term “below” can encompass both anorientation of above and below. The device may be otherwise oriented(e.g., rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

As used herein, the singular forms “a”, “an”, and “the” are intended toinclude the plural forms as well, unless the context indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising” specify the presence of stated features, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, steps, operations,elements, components, and/or groups thereof.

The term “object” generally refers to a component or group ofcomponents. For example, an object may refer to either a pocket or aboss of a disk within the specification or claims. Throughout thespecification and claims, the terms “object”, “component”, “portion”,“part”, and “piece” are used interchangeably.

Lastly, the terms “or” and “and/or” as used herein are to be interpretedas inclusive or meaning any one or any combination. Therefore, “A, B orC” or “A, B and/or C” mean “any of the following: A; B; C; A and B; Aand C; B and C; A, B and C.” An exception to this definition will occuronly when a combination of elements, functions, steps or acts are insome way inherently mutually exclusive.

FIG. 1 is a view of an illustrative patient-side portion 100 of ateleoperated surgical system, in accordance with embodiments of thepresent invention. The patient-side portion 100 includes supportassemblies 110 and one or more surgical instrument manipulators 112 atthe end of each support assembly. The support assemblies optionallyinclude one or more unpowered, lockable setup joints that are used toposition the surgical instrument manipulator(s) 112 with reference tothe patient for surgery. As depicted, the patient-side portion 100 restson the floor. In other embodiments the patient-side portion may bemounted to a wall, to the ceiling, to the operating table 126, whichalso supports the patient's body 122, or to other operating roomequipment. Further, while the patient-side portion 100 is shown asincluding four manipulators 112, more or fewer manipulators 112 may beused. Still further, the patient-side portion 100 may consist of asingle assembly as shown, or it may include two or more separateassemblies, each optionally mounted in various possible ways.

Each surgical instrument manipulator 112 supports one or more surgicalinstruments 120 that operate at a surgical site within the patient'sbody 122. Each manipulator 112 may be provided in a variety of formsthat allow the associated surgical instrument to move with one or moremechanical degrees of freedom (e.g., all six Cartesian degrees offreedom, five or fewer Cartesian degrees of freedom, etc.). Typically,mechanical or control constraints restrict each manipulator 112 to moveits associated surgical instrument around a center of motion on theinstrument that stays stationary with reference to the patient, and thiscenter of motion is typically located to be at the position where theinstrument enters the body.

The term “surgical instrument” is used herein to describe a medicaldevice configured to be inserted into a patient's body and used to carryout surgical or diagnostic procedures. The surgical instrument typicallyincludes an end effector associated with one or more surgical tasks,such as a forceps, a needle driver, a shears, a bipolar cauterizer, atissue stabilizer or retractor, a clip applier, an anastomosis device,an imaging device (e.g., an endoscope or ultrasound probe), and thelike. Some surgical instruments used with embodiments of the inventionfurther provide an articulated support (sometimes referred to as a“wrist”) for the end effector so that the position and orientation ofthe end effector can be manipulated with one or more mechanical degreesof freedom in relation to the instrument's shaft. Further, many surgicalend effectors include a functional mechanical degree of freedom, such asjaws that open or close, or a knife that translates along a path.Surgical instruments may also contain stored (e.g., on a semiconductormemory inside the instrument) information that may be permanent or maybe updatable by the surgical system. Accordingly, the system may providefor either one-way or two-way information communication between theinstrument and one or more system components.

A functional teleoperated surgical system will generally include avision system portion (not shown) that enables the operator to view thesurgical site from outside the patient's body 122. The vision systemtypically includes a surgical instrument that has a video-image-capturefunction 128 (a “camera instrument”) and one or more video displays fordisplaying the captured images. In some surgical system configurations,the camera instrument 128 includes optics that transfer the images fromthe proximal end of the camera instrument 128 to one or more imagingsensors (e.g., CCD or CMOS sensors) outside of the patient's body 122.Alternatively, the imaging sensor(s) may be positioned at the proximalend of the camera instrument 128, and the signals produced by thesensor(s) may be transmitted along a lead or wirelessly for processingand display on the video display. An illustrative video display is thestereoscopic display on the surgeon's console in surgical systemscommercialized by Intuitive Surgical, Inc., Sunnyvale, Calif.

A functional teleoperated surgical system will further include a controlsystem portion (not shown) for controlling the movement of the surgicalinstruments 120 while the instruments are inside the patient. Thecontrol system portion may be at a single location in the surgicalsystem, or it may be distributed at two or more locations in the system(e.g., control system portion components may be in the system'spatient-side portion 100, in a dedicated system control console, or in aseparate equipment rack). The teleoperated master/slave control may bedone in a variety of ways, depending on the degree of control desired,the size of the surgical assembly being controlled, and other factors.In some embodiments, the control system portion includes one or moremanually-operated input devices, such as a joystick, exoskeletal glove,a powered and gravity-compensated manipulator, or the like. These inputdevices control teleoperated motors which, in turn, control the movementof the surgical instrument.

The forces generated by the teleoperated motors are transferred viadrivetrain mechanisms, which transmit the forces from the teleoperatedmotors to the surgical instrument 120. In some telesurgical embodiments,the input devices that control the manipulator(s) may be provided at alocation remote from the patient, either inside or outside the room inwhich the patient is placed. The input signals from the input devicesare then transmitted to the control system portion. Persons familiarwith telemanipulative, teleoperative, and telepresence surgery will knowof such systems and their components, such as the da Vinci® SurgicalSystem commercialized by Intuitive Surgical, Inc. and the Zeus® SurgicalSystem originally manufactured by Computer Motion, Inc., and variousillustrative components of such systems.

As shown, both the surgical instrument 120 and an optional entry guide124 (e.g., a cannula in the patient's abdomen) are removably coupled tothe proximal end of a manipulator 112, with the surgical instrument 120inserted through the entry guide 124. Teleoperated actuators in themanipulator 112 move the surgical instrument 120 as a whole. Themanipulator 112 further includes an instrument carriage 130. Thesurgical instrument 120 is detachably connected to the carriage 130. Theteleoperated actuators housed in the carriage 130 provide a number ofcontroller motions which the surgical instrument 120 translates into avariety of movements of the end effector on the surgical instrument.Thus the teleoperated actuators in the carriage 130 move only one ormore components of the surgical instrument 120 rather than theinstrument as a whole. Inputs to control either the instrument as awhole or the instrument's components are such that the input provided bya surgeon to the control system portion (a “master” command) istranslated into a corresponding action by the surgical instrument (a“slave” response).

FIG. 2 is a side view of an illustrative embodiment of the surgicalinstrument 120, comprising a proximal portion 250 and a distal controlmechanism 240 coupled by an elongate tube 210. The proximal portion 250of the surgical instrument 120 may provide any of a variety of endeffectors such as the forceps 254 shown, a needle driver, a cauterydevice, a cutting tool, an imaging device (e.g., an endoscope orultrasound probe), or a combined device that includes a combination oftwo or more various tools and imaging devices. In the embodiment shown,the end effector 254 is coupled to the elongate tube 210 by a “wrist”252 that allows the orientation of the end effector to be manipulatedwith reference to the instrument tube 210.

Referring to FIG. 3A, an exemplary embodiment of a surgical instrument120, a control surface 310 of a teleoperated actuated surgicalinstrument carriage 130 and an instrument sterile adapter (ISA) 300illustrated in a coupled condition is shown. The control surface 310 iscoupled to the surgical instrument 120 to provide control of thesurgical instrument. The ISA 300 extends the control surface 310 of theinstrument carriage 130 to provide a disposable sterile equivalent ofthe control surface that is in direct contact with the surgicalinstrument 120.

Referring to FIG. 3B, an exemplary embodiment of the coupler system ofFIG. 3A is provided. In the first stage of the coupling process, theunderside of the ISA 300 is coupled with the control surface 310 on thetopside of the carriage 130. Specifically, the carriage drivers 320 matewith the underside of the corresponding ISA couplers 330. Next, thesurgical instrument 120 is coupled with the topside of the ISA 300. Thetopside of the ISA couplers 330 mate with corresponding instrumentdrivers (not shown).

However, the addition of an ISA 300 between the coupling of the surgicalinstrument 120 and the teleoperated actuated surgical instrumentcarriage 130 creates a need to determine if the instrument sterileadapter is present and properly engaged with the teleoperated actuatedsurgical instrument carriage 130. Similarly, there is a need todetermine if the surgical instrument 120 is present and properly engagedwith the instrument sterile adapter 300.

Installation of an Instrument Sterile Adapter and Surgical Instrument

Referring to FIG. 4, an exemplary embodiment of a control surface 310 ofthe carriage 130 from a top perspective including detection pins410A-410D is shown. The detection pins 410A-410D are shown in oneconfiguration; however, in other embodiments, the detection pins410A-410D may be provided in other configurations as would be recognizedby one of ordinary skill in the art.

Referring to FIG. 5, an illustration of an exemplary embodiment of thedetection pins 410A-410D relative to the circuit board 561 and thesensors 560A-560D is shown. The detection pin 410A includes the distalend 411A with a sensing tip 510A, the proximal end 412A, a shaft 520A, ashoulder 521A of the shaft 520A, a spring 530A, an upstop 540A and amagnet housing 550A. The magnet housing 550A includes a magnet having amagnet face 551A, which faces the sensor 560A. Each of the detectionpins 410B-410D include the same components as 410A.

The shaft 520A and the magnet housing 550A move as a single assemblywithin the upstop 540A and the distal end 411 A bushing. The upstop 540Alimits the upward travel of the shaft 520A and the magnet housing 550Aat the point where a larger diameter of the shaft 520A at the proximalend 412A is unable to pass through the upstop.

The spring 530A is captive between the upstop 540A and the shoulder 521Aof the shaft 520A. As a result, the spring 530A urges the shaft 520Aupwardly toward the distal end 411A. A downward force can be applied tothe distal end 411 A of the shaft 520A to move the shaft and theattached magnet housing 550A toward the sensor 560A. The distal end411C-411D of the detection pin 410C-410D may be wholly or partiallycontained in a carriage well 420C-420D (better seen in FIG. 6A) thatprotects the detection pin from application of sideward forces thatcould damage the detection pin.

As is illustrated in FIGS. 6A-6C, which are section views taken alongsection line 6A-6A of FIG. 4, some of the detection pins 410A-410B maybe shorter in length than others of the detection pins 410C-410D. In oneembodiment, the shorter detection pins 410A-410B may be about 1.25millimeters (0.050 inches) shorter than the longer detection pins410C-410D, for example.

The circuit board 561, which is mechanically fixed to the instrumentcarriage 130, includes analog Hall effect sensors 560A-560D (hereinafterreferred to as “sensors”), which provide a signal responsive to thedistance between the magnets and the sensors 560A-560D. The Hall effectsensors 560A-560D may include circuitry that provides a digital signalbased on the analog signal produced by Hall effect. In one embodiment,the distance between the magnets of each of the detection pins 410A-410Benables a determination of whether the ISA 300 is present and engagedwith the carriage 130. For example, the sensor 560A may sense theamplitude of the magnetic field generated by the magnet and may providean output voltage or digital value responsive to the distance betweenthe magnet face of the detection pin 410A and the sensor 560A. As thedistance decreases, the output voltage or digital value may increase.

In such an example, the ISA 300 may be considered to be present andfully engaged with the carriage 130 when the output threshold of both ofthe sensors 560A-560B exceeds a first predetermined threshold.

In such an example, the sensors 560C-560D may determine the distancebetween the magnets and the sensors 560C-560D. The distance between themagnets of each of the detection pins 410C-410D enables a determinationof whether the surgical instrument 120 is present and engaged with theISA 300.

In one embodiment, the sensors 560A-560D may be calibrated as part of acalibration procedure during the assembly of the instrument carriage130. As an example, during assembly, a calibration block may be placedon the control surface 310 of the instrument carriage 130 to depress thedetection pins 410A-410D a known amount. The output voltage or digitalvalue provided by the sensors 560A-560D upon application of thecalibration block may then be stored in a carriage controller 340 andused as a threshold value to determine if the ISA 300 or the surgicalinstrument 120 is present and engaged.

Referring the FIG. 6A, an exemplary embodiment of the plurality ofdetection pins 410A-410D of the carriage 130 of FIG. 4 relative to thesurgical instrument 120, the ISA 300 and the circuit board 561 prior theengagement of the ISA 300 with the control surface 310 of the carriage130 is shown. The detection pins 410A-410D are coupled to the instrumentcarriage 130 which provides the mechanical ground to which motion of thedetection pins is referenced. The circuit board 561 and the attachedHall effect sensors 560A-560D are also mechanically fixed to theinstrument carriage 130 allowing motion of the detection pins to bereferenced to the sensors. The distal end 411A of the detection pin 410Aextends from the control surface 310 to the sensing tip 510A. In theembodiment of FIG. 6A, the carriage 130 includes the detection pins410A-410D, although only the detection pins 410A and 410C-410D arevisible. In one embodiment, the detection pins 410A-410B may be used todetect the presence and engagement of the ISA 300 and the detection pins410C-410D may be used to detect the presence and engagement of thesurgical instrument 120.

In FIGS. 6A-6C, the upstops 540A-540D are shown fixed to the instrumentcarriage 130. Therefore, the upstops 540A-540D provide a fixed point ofreference that limits the upward travel of the magnet face 551A awayfrom the sensor 560A to a known distance.

Referring to FIG. 6B, the exemplary embodiment of the plurality ofdetection pins 410A-410D of the carriage 130 of FIG. 4 relative to theISA 300 and the circuit board 561 upon the engagement of the ISA 300with the control surface 310 of the carriage 130 is shown. The ISA 300includes a flat surface 610A that comes in contact with the sensing tip510A of the detection pins 410A upon engagement of the ISA 300 with thecontrol surface 310 of the carriage 130. As a result of the engagementof the ISA 300 with the control surface 310 of the carriage 130, asurface of the ISA 300 depresses the detection pins 410A-410B into thecarriage wells 420A-420B. As mentioned above, the detection pins410A-410B may be shorter in length than the detection pins 410C-410D toaccommodate the heights of the surfaces they contact on the ISA 300.

The ISA 300 also includes presence pins 610C-610D that are configured tocontact the detection pins 410C-410D upon engagement of the ISA 300. Asseen in FIG. 6A, the presence pins 610C-610D are in their lowermostposition when the ISA 300 is not engaged with the control surface 310 ofthe carriage 130. Engaging the ISA 300 lifts the presence pins 610C-610Dwithin the ISA as seen in FIG. 6B.

As the detection pins 410A-410B operate in the same manner, thefollowing discussion of FIG. 6B will refer to the operation of thedetection pin 410A for simplicity, unless otherwise noted. Thedepression of the detection pin 410A causes the spring 530A to compressdue to force applied from the shoulder 521A of the shaft 5201 applyingpressure toward the proximal end 412A of the detection pin 410A. Thespring 530A compresses against the upstop 540A, which, as discussedabove, is fixed to the carriage 130. As the detection pin 410A isdepressed by the engagement of the ISA 300, the detection pin 410Aslides through the upstop 540A as the proximal end 412A of the detectionpin 410A approaches the sensor 560A. As the proximal end 412A of thedetection pin 410A approaches the sensor 560A, the magnetic fieldproduced by the magnet contained in the magnet housing 550A causes theoutput voltage or digital value of the sensor 560A to increase. When theoutput voltage or values of both of the sensors 560A-560B, correspondingto the detection pins 410A-410B respectively, exceeds a firstpredetermined threshold, which may be a threshold set by a calibrationprocess as described above, the ISA 300 is considered to be present andfully engaged with the control surface 310 of the carriage 130.

Referring now to FIG. 6C, the exemplary embodiment of the plurality ofdetection pins 410A-410D of the carriage 130 of FIG. 4 relative to thesurgical instrument 120, the ISA 300 and the circuit board 561 upon theengagement of the surgical instrument 120 with the ISA 300 is shown. Asthe surgical instrument 120 engages with the ISA 300, the surgicalinstrument 120 makes contact with and depresses the presence pins610C-610D. In turn, the depression of the presence pins 610C-610Ddepresses the detection pins 410C-410D on the control surface 310 of thecarriage 130. Upon contacting the detection pins 410C-410D, the presencepins 610C-610D depress the detection pins 410C-410D into the carriagewells 420C-420D.

As the detection pins 410C-410D are depressed by the engagement of thesurgical instrument 120 with the ISA 300, the detection pins 410C-410Dslide through the upstops 540C-540D, respectively. Subsequently, theproximal ends 412C-412D of each of the detection pins 410C-410D approachthe corresponding sensor of the sensors 560C-560D. As the proximal ends412C-412D of the detection pins 410C-410D approach the sensors560C-560D, the magnetic fields produced by the magnet faces 551C-551Dcause the output voltage or digital values of the sensors 560C-560D toincrease. When the output voltage of both of the sensors 560C-560Dexceeds a second predetermined threshold, which may be a threshold setby a calibration process as described above, the surgical instrument 120is considered to be present and fully engaged with the ISA 300.

It will be appreciated that the presence of the ISA or the surgicalinstrument could be detected by a single detection pin or sensor. Twodetection pins or sensors may be used so that partial engagement withthe ISA or the surgical instrument at an angle to the receiving surfacecan be detected. Two detection pins or sensors may also be used todetect inconsistent outputs from the two sensors that may indicate aneed for system service.

FIG. 7 illustrates the response of a digital output from one embodimentof a Hall effect sensor. The sensitivity of an analog Hall effect sensorincreases as a magnet moves closer to the sensor. As the distancebetween the magnet face 551A and the sensor 560A decreases, e.g., theISA 300 is engaging with the control surface 310 of the carriage 130,the number of bits of resolution per micrometer of travel increases fora sensor with digital output values. For example, for the embodiment ofthe sensor illustrated, when the distance between magnet face 551A andthe sensor 560A is greater than 2 mm., a change of 1 bit in the digitaloutput value represents more than 1 micrometer of travel. When thedistance between magnet face 551A and the sensor 560A is less than 1mm., 1 micrometer of travel will produce a change of more than 1 bit inthe digital output value.

Referring to FIGS. 8A-8D, a plurality of states of the detection pin areshown. FIG. 8A illustrates the sensing tip 510 of the detection pin atan uppermost state, e.g., a first state 801. First state 801 mayrepresent the sensing tip 510 of the detection pin in its uppermostposition, which may be termed the first depression point. FIG. 8Billustrates the sensing tip 510 of the detection pin at a seconddepression point, e.g., a second state 802. FIG. 8C illustrates thesensing tip 510 of the detection pin at a third depression point, e.g.,a third state 803. FIG. 8D illustrates the sensing tip 510 of thedetection pin at a fourth depression state, e.g., a fourth state 804. Itwill be seen that the four depression states are increasingly closertogether as the magnet face 551A approaches the sensor 560A and theresolution of the output values increases. The four depression statesmay be chosen such that the difference in output values is approximatelyequal between each pair of adjacent depression states.

Based on the detection of multiple states, the invention may beimplemented using two rather than four detection pins to detect both theISA 300 and the surgical instrument 120. The detection of multiplestates may further allow the detection of different instrument orinstrument adapter types, such as distinguishing a surgical instrumentfrom an endoscopic camera.

The second through fourth states 802-804 may represent one or more of(i) a portion of the engagement with the ISA 300 has been completed,(ii) the ISA 300 is fully engaged with the control surface 310 of thecarriage 130, (iii) a portion of the engagement process between thesurgical instrument 120 and the ISA 300 has been completed, (iv) theengagement process between the surgical instrument 120 and the ISA 300has been completed, (v) a second surgical instrument, different than thesurgical instrument 120, has completed a portion of the engagementprocess with the ISA 300, and/or (vi) the second surgical instrument hascompleted the engagement process with the ISA 300. Additionally, one ormore of the states may signify that the second surgical instrument, thesurgical instrument 120 and/or the ISA 300 are disengaging or havecompletely disengaged from the control surface 310 of the carriage 130.

As an illustrative example, using only two detection pins, the firststate 801 may represent that no contact has been made with the controlsurface 310 of the carriage 130. In one embodiment, upon contact withthe detection pins 410C-410D, the presence pins 610C-610D are raised toan uppermost position within the ISA 300. As the ISA 300 engages withthe control surface 310 of carriage 130, the presence pins 610C-610D mayreach the upward limit of their travel within the ISA and depress thedetection pins 410A-410B to the second state 802. When both of thedetection pins are at the second state 802, the ISA 300 may be presentand fully engaged with the control surface 310 of the carriage 130.

As the surgical instrument 120 engages with the ISA 300, the surgicalinstrument 120 makes contact with and depresses the presence pins610C-610D. In turn, the depression of the presence pins 610C-610Ddepresses the detection pins 410C-410D on the control surface 310 of thecarriage 130. When both of the detection pins are at the third state803, the surgical instrument 120 may be present and fully engaged withthe ISA 300. When both of the detection pins are at the fourth state804, a second type of surgical instrument may be present and fullyengaged with the ISA 300.

Additionally, in one embodiment, the surgical instrument 120 may includea radio-frequency identification (RFID) tag. In such an embodiment, uponbeginning an engagement process, the RFID tag may provide theteleoperated actuated surgical instrument manipulator with identifyinginformation of the surgical instrument 120. Such identifying informationmay be used to determine which state of the detection pins, as discussedabove, is necessary to consider the surgical instrument 120 as fullyengaged with the ISA 300. For example, the teleoperated actuatedsurgical instrument manipulator may read the RFID tag of the surgicalinstrument 120 to require the detection pins 410C-410D to be depressedfor at least a first predetermined amount of time at the third state 803to conclude the surgical instrument 120 is engaged with the ISA 300.Alternatively, the teleoperated actuated surgical instrument manipulatormay read the RFID tag of the second surgical instrument to require thedetection pins 410C-410D to be depressed for at least a secondpredetermined amount of time at the fourth state 804 to conclude thesecond surgical instrument is engaged with the ISA 300. Herein, thefirst predetermined amount of time and the second predetermined amountof time may or may not be equivalent in length.

Removal of the Surgical Instrument and the Instrument Sterile Adapter

As with the installation of the surgical instrument 120, when removingthe surgical instrument 120, readings may be taken from both of thedetection pins 410C-410D. In one embodiment, both sensors 560C-560D arerequired to provide an output voltage below a third threshold todetermine that the surgical instrument has been removed. The thirdthreshold may be set as a predetermined amount less than the secondthreshold used to determine the presence of the surgical instrument. Thedifference between the second and third thresholds may provide ahysteresis effect in which a detection pin that has detected thepresence of the surgical instrument has to move a significant distanceupward before detecting the removal of the surgical instrument.

In one embodiment, the removal of the surgical instrument 120 may bedetected by the teleoperated actuated surgical instrument manipulatorusing a three-phase system. First, the teleoperated actuated surgicalinstrument manipulator detects the change in output voltage from thesensors 560C-560D. Second, the surgical instrument 120 may include a

RFID tag, as discussed above. As the surgical instrument 120 disengagesfrom the control surface 310 of the carriage 130 and moves away from theteleoperated actuated surgical instrument manipulator, the teleoperatedactuated surgical instrument manipulator will eventually no longer beable to detect the RFID tag. Third, the surgical instrument 120 mayinclude a magnet. Subsequent to the inability of the teleoperatedactuated surgical instrument manipulator to detect the RFID tag, as thesurgical instrument 120 is moved away from the control surface 310 ofthe carriage 130, the teleoperated actuated surgical instrumentmanipulator will eventually no longer be able to detect the magnet.Therefore, in an embodiment employing a three-phase detection system,the teleoperated actuated surgical instrument manipulator will determinethe surgical instrument 120 has been removed from the surgicalinstrument manipulator only upon detecting (i) the change in outputvoltage by both sensors 560C-560D below a third threshold, (ii) theinability to read the RFID tag of the surgical instrument 120, and (iii)the inability to detect the magnet of the surgical instrument 120.

Additionally, the detection of the removal of the ISA 300 is performedin a similar manner. The teleoperated actuated surgical instrumentmanipulator detects a change in the output voltage of the sensors560A-560B. When both of the sensors 560A-560B provide an output voltagebelow a fourth threshold, the teleoperated actuated surgical instrumentmanipulator may determine the ISA 300 has been completely disengaged andremoved from the control surface 310 of the carriage 130. As discussedin connection with the second and third thresholds for the surgicalinstrument detection, a difference between the first and fourththresholds may provide hysteresis in detecting the presence and removalof the ISA. As discussed above, the surgical instrument 120 may utilizea RFID tag in the detection of the removal process. Similarly, the ISA300 may include a RFID tag for utilization in the removal process aswell.

The plurality of thresholds stated above are not necessarily allequivalent nor are one or more of the plurality of thresholdsnecessarily equivalent. However, all of the thresholds may be equivalentin one embodiment, one or more may be equivalent in a second embodiment,and all may be different in a third embodiment.

While certain exemplary embodiments have been described and shown in theaccompanying drawings, it is to be understood that such embodiments aremerely illustrative of and not restrictive on the broad invention, andthat this invention is not limited to the specific constructions andarrangements shown and described, since various other modifications mayoccur to those of ordinary skill in the art. The description is thus tobe regarded as illustrative instead of limiting.

1. An instrument carriage for providing control of a surgical instrumentattached to the instrument carriage, the instrument carriage comprising:a control surface that attaches to the surgical instrument to providecontrol of the surgical instrument; a first detection pin coupled to theinstrument carriage, the first detection pin having a first distal endthat extends from the control surface; a first magnet fixed to a firstproximal end of the first detection pin; a carriage controller; acircuit board fixed to the instrument carriage; a first Hall effectsensor fixed to the circuit board facing the first magnet, the firstHall effect sensor providing a first output signal that iscommunicatively coupled to the carriage controller, the carriagecontroller providing an indication that the surgical instrument ispresent on the instrument carriage when movement of the first detectionpin causes the first output signal to exceed a first instrument presencethreshold value that is stored in the carriage controller as part of acalibration procedure during assembly of the instrument carriage.
 2. Theinstrument carriage of claim 1 wherein the carriage controller providesan indication that an instrument sterile adapter (ISA) is present on theinstrument carriage when movement of the first detection pin causes thefirst output signal to exceed a first ISA threshold value that is storedin the carriage controller as part of the calibration procedure duringassembly of the instrument carriage.
 3. The instrument carriage of claim1 wherein an instrument sterile adapter is attached to the instrumentcarriage and the surgical instrument is attached to the instrumentcarriage through the instrument sterile adapter, the instrument sterileadapter including a first presence pin to extend the first distal end ofthe first detection pin.
 4. The instrument carriage of claim 1 whereinthe carriage controller provides an indication that the surgicalinstrument is removed from the instrument carriage when movement of thefirst detection pin causes the first output signal to be less than afirst instrument removal threshold value that is less than the firstinstrument presence threshold value.
 5. The instrument carriage of claim1 wherein the control surface includes a well and the first distal endis within the well to protect the first detection pin from horizontalforces.
 6. The instrument carriage of claim 1 further comprising: asecond detection pin coupled to the instrument carriage, the seconddetection pin having a second distal end that extends from the controlsurface spaced apart from the first distal end; a second magnet fixed toa second proximal end of the second detection pin; a second Hall effectsensor fixed to the circuit board facing the second magnet, the secondHall effect sensor providing a second output signal that iscommunicatively coupled to the carriage controller, the carriagecontroller providing the indication that the surgical instrument ispresent on the instrument carriage further requires movement of thesecond detection pin causing the second output signal to exceed a secondinstrument presence threshold value that is stored in the carriagecontroller as part of the calibration procedure during assembly of theinstrument carriage.
 7. A method for detecting presence a surgical of asurgical instrument coupled to an instrument carriage, the methodcomprising: receiving a first output signal from a first sensor fixed inposition relative to the instrument carriage, the first output signalbeing responsive to motion of a first detection pin created by presenceof the surgical instrument; calibrating the first sensor by depressingthe first detection pin a first known distance and storing a firstinstrument presence threshold value according to the first outputsignal; and indicating that the surgical instrument is present on theinstrument carriage when movement of the first detection pin causes thefirst output signal to exceed the first instrument presence thresholdvalue.
 8. The method of claim 7 further comprising: storing a first ISAthreshold value that is less than the first instrument presencethreshold value; and indicating that an instrument sterile adapter (ISA)is present on the instrument carriage when movement of the firstdetection pin causes the first output signal to exceed the first ISAthreshold value.
 9. The method of claim 7 further comprising: attachingan instrument sterile adapter to the instrument carriage to receive thesurgical instrument; and extending a first distal end of the firstdetection pin with a first presence pin that is loosely held within theinstrument sterile adapter.
 10. The method of claim 7 further comprisingindicating that the surgical instrument is removed from the instrumentcarriage when movement of the first detection pin causes the firstoutput signal to be less than a first instrument removal threshold valuethat is less than the first instrument presence threshold value.
 11. Themethod of claim 7 further comprising protecting the first detection pinfrom horizontal forces by locating a first distal end of the firstdetection pin within a well.
 12. The method of claim 7 furthercomprising: receiving a second output signal from a second sensor fixedin position relative to the instrument carriage, the second outputsignal being responsive to motion of a second detection pin created bypresence of the surgical instrument; calibrating the second sensor bydepressing the second detection pin a second known distance and storinga second instrument presence threshold value according to the secondoutput signal; and indicating that the surgical instrument is present onthe instrument carriage only when movement of the second detection pincauses the second output signal to exceed the second instrument presencethreshold value in addition to the first output signal exceeding thefirst instrument presence threshold value.
 13. The method of claim 7wherein calibrating the first sensor further comprises depressing thefirst detection pin a third known distance and storing a thirdinstrument presence threshold value according to the first outputsignal, and the method further comprises indicating an additional stateof the surgical instrument when movement of the first detection pincauses the first output signal to be more than the third instrumentpresence threshold value.
 14. The instrument carriage of claim 1 whereinthe carriage controller provides an indication of an additional state ofthe surgical instrument when movement of the first detection pin causesthe first output signal to exceed a third instrument presence thresholdvalue that is stored in the carriage controller as part of thecalibration procedure during assembly of the instrument carriage.
 15. Aninstrument carriage for providing control of a surgical instrumentattached to the instrument carriage, the instrument carriage comprising:a control surface that attaches to the surgical instrument to providecontrol of the surgical instrument; a first detection pin coupled to theinstrument carriage, the first detection pin having a first distal endthat extends from the control surface; a first magnet fixed to a firstproximal end of the first detection pin; means for providing anindication that the surgical instrument is present on the instrumentcarriage responsive to movement of the first detection pin.
 16. Theinstrument carriage of claim 15 wherein the means for providing anindication further provides an indication that an instrument sterileadapter (ISA) is present on the instrument carriage responsive tomovement of the first detection pin.
 17. The instrument carriage ofclaim 15 wherein the means for providing an indication further providesan indication that the surgical instrument is removed from theinstrument carriage responsive to movement of the first detection pin.18. The instrument carriage of claim 15 wherein the means for providingan indication further provides an indication of an additional state ofthe surgical instrument responsive to movement of the first detectionpin.